Cartons having self-forming,self-leveling bottoms



y 3, 1969 L. ADAMS, JR 3,443,739

CARTONS HAVING SELF-FORMING, SELF-LEVELING BOTTOMS Filed March 16, 1967 Sheet of 2 Arrow/5x I..- ADAMS, JR

May 13, 1969 CARTONS HAVING SELF-FORMING, SELF-LEVELING BOTTOMS Sheet 2 of Filed March 16, 1967 IN VISA/TOR. LEON/4P0 Al /4M5 (JR ATTORNEYS United States Patent US. Cl. 229-39 8 Claims ABSTRACT OF THE DISCLOSURE A flat-foldable carton having a simulated pre-wrap thereon and a self-forming, self-leveling bottom. The bottom closure flaps are formed with tug tabs which can be folded and sandwiched between certain ones of the bottom closure flaps and affixed to these bottom closure flaps in a fashion such as to provide back (board) to face anchor points, as opposed to face to face anchor points, between them. The simulated pre-wrap is made discontinuous along the portion thereof adjacent the bottom closure flaps, so as to permit the tug tabs to be folded in the described manner. Upon erecting the carton from a fiat-folded position, the bottom is automatically formed and leveled.

This invention relates to cartons for packaging articles and, in particular, to cartons having a simulated pre wrap thereon and self-forming bottoms.

In the instant application, what is meant by a simulated pre-wrap is a decorative or protective covering which is spot glued or otherwise primarily loosely fixed to a carton to simulate gift wrapping, as distinguished fro-m cartons with a decorative exterior covering which is laminated to the cartons. Cartons of the simulated prewrap type are used extensively to gift-package a whole host of products, particularly at Christmas time and other seasonal occasions. The simulated pre-wrap may take the form of a colored metallic foil or a naturally glossy or highly lacquered material having a decorative design.

The pre-wraps are applied to the cartons so that the cartons can be shipped flat folded and thereafter erected or opened. Upon being opened, by exerting pressure of the remote edges of the flat folded carton, the pre-wrap simulates a gift-wrapped package. A removable identification band also may be aflixed to the carton, as disclosed in US. Patent 2,950,040 to Bolding. Such a carton desirably has a collapsible locking bottom.

Presently available cartons of the simulated pre-wrap type and the methods of forming them suffer several disadvantages which the carton industry has been trying to eliminate, without success. For example, with the methods presently used to form the cartons, the pre-wrap is in face-to-face relationship at the seals. These seals many times break, thereby destroying the attractiveness and the utility of the carton, since it is generally diflicult to effect a good seal between two glossy or highly lacquered finishes using standard glueing techniques. Hot melts or other special sealing techniques must be used and this, of course, substantially increases manufacturing costs. The simulated pre-wrap sealing problem has plagued the industry for some time. Thus far, the accepted solution is to extend the length of the bottom closure flaps so that they can be afiixed to one another so as to provide a board-to-board sealing surface. This solution is not entirely satisfactory for the seals still open. Furthermore, additional material is required.

Another undesirable feature is that the self-forming bottoms fail to fully close to provide a level bottom on the cartons. During the carton erecting operation someone must insert his fist or other object into the carton,

3,443,739 Patented May 13, 1969 to actually flatten or level the bottom. In most produc tion lines, this necessity of flattening or leveling the bottoms causes a substantial slow-down in the operation or, in the alternative, forces the assembler to use exceedingly expensive wrapping equipment for the standard type carton.

Accordingly, it is an object of the present invention to provide improved cartons for packaging articles.

More particularly, it is an object to provide improved cartons having a simulated pre-wrap thereon and a selfform bottom.

Another object is to provide improved cartons of the described type, constructed in a fashion such that the self-forming bottoms thereof are also self-leveling.

Still another object is to provide improved cartons of the above type having stronger seals. In this respect, it is contemplated that the face-to-face relationship of the pre-wrap be eliminated so as to effect a better seal.

Still another object is to provide improved cartons of the above type which are formed in a fashion such as to provide a substantial saving in material requirements.

A still further object is to provide improved cartons of the above type which can be more easily and more quickly erected, with the same presently available, generally used equipment and without the necessity of inserting an object into the carton to level its bottom.

Other objects of the invention will in part be obvious and will in part appear hereinafter.

For a fuller understanding of the nature and objects of the invention, reference should be had to the following detailed description taken in connection with the accompanying drawings in which:

FIG. 1 is a perspective view of a carton having a selfforming, self-leveling bottom which is constructed in accordance with the present invention;

FIG. 2 is a bottom view of the carton of FIG. 1, illustrating the appearance of the self-forming, self-leveling bottom when the carton is erected;

FIG. 3 is a plan view of the blank of sheet material from which the carton is formed;

FIGS. 4-7 are views illustrating the manner in which the blank of FIG. 3 is folded to provide the self-forming, self-leveling bottom; and

FIGS. 8-11 are views generally illustrating the manner in which the four closure flaps operate inopening to form the bottom of the carton.

Similar reference characters refer to similar parts throughout the several views of the drawings.

Referring now to the drawings, in FIG. 1 there is shown a carton 10 which has a simulated pre-wrap 12 thereon and a self-forming, self-leveling bottom 13 which, when formed, has the appearance shown in FIG. 2. The carton 10 is formed from a blank 14, as shown in FIG. 3, which is cut from a single sheet of appropriate material, such as paperboard, generally used in making cartons of the described type. The pre-wrap 12 is aflixed to one surface of the blank 14 as described more fully below, before it is folded.

The blank 14 is generally rectangular-shaped and has a number of parallel, vertically disposed score lines 16- 20 on it which divide the blank into four side walls 22- 25 which, as illustrated, are of equal width so as to form a square carton. The side walls can be formed having Widths so as to form rectangular cartons also. In such a case, the size of the top and bottom closure flaps are correspondingly formed. Integrally formed with the side walls 22 and 25, along the score lines 16 and 20, are glue flaps 28 and 29, respectively.

Two parallel, horizontally disposed score lines 30 and 32 also are formed on the blank 14, along the upper and lower portions thereof, respectively. Above the score line 30, as illustrated, are four top closure flaps 34-37 which are extensions of the respective side walls 22-25 and which, when the carton is erected, form the top wall thereof. The closure flaps 34-37 may be of any one of a number of different configurations which are functionalto provide a closed top wall.

Below the score line 32, as illustrated, are four bottom closure flaps 40-43 which also are extensions of the respective side walls 22-25 and which, when formed and folded in the manner described more fully below, provide the self-forming, self-leveling bottom 13 for the carton.

The surface of the blank 14 opposite to that shown forms the exterior of the carton 10, and to this surface is afiixed the pre-wrap 12. The pre-wrap 12, as indicated above, can be colored metallic foil, a highly lacquered sheet material having a decorative design on it, or any one of a number of different types of material. The prewrap 12 extends across the exterior side of the blank 14 and is spot glued, as opposed to being laminated, to it. At the top and bottom edges of the side walls 22-25, the pre-wrap overlaps the top closure flaps 34-37 and the bottom closure flaps 40-43 sufficiently to provide a strip above and below the score lines and 32, respectively, which is equal to at least one-half the cross-sectional width of the carton 10. The side edges of the pre-wrap 12 can overlap only a portion of the glue flaps 28 and 29 and be afiixed to them as illustrated. Alternatively, the pre-wrap can be extended beyond the edges of the glue flaps, folded over and afiixed to them on the surface thereof which is shown. The overlap of the pre-wrap 12 is such that the blank 14 is completely concealed when the carton 10 is erected, to simulate a gift package which has been hand wrapped. To this extent, the carton blank 14 with the simulated pre-wrap 12 aflixed to it is constructed in generally the same manner in which it has been constructed in the past.

In accordance with the present invention, the abovementioned disadvantages of the presently available cartons of the simulated pro-wrap type are eliminated by making the pre-wrap 12 discontinuous along its lower edge portion which is adjacent to the bottom closure flaps -43 and which is aflixed to one or more of them. More specifically, the pre-wrap 12 is cut at two positions, and optionally at a third position, between the bottom closure fiaps 40-43. These cuts are preferably simply in the form of slits 46 and 48, as illustrated, however, they also can be in the form of slots or other configurations which will interrupt the pre-wrap along this lower edge portion so as to permit the bottom closure flaps 40-43 to be folded in the manner described below. These cuts can be easily made and the bottom closure flaps folded on the same folding machines which are used at the present time, with little modification to them. Accordingly, the same folding machines can be used to provide substantially improved cartons.

Referring now to FIG. 3, it can be seen that the slits 46 and 48 are formed in the pre-wrap 12 between the bottom closure flaps 40 and 41, and between the bottom closure flaps 42 and 43, respectively, so as to extend in line with the score lines 17 and 19, from the edge of the pre-wrap 12 substantially to the score line 32. A third slit (not shown) can be provided between the bottom closure flaps 41 and 42, if desired, however, the two slits 46 and 48 are generally the only ones necessary to provide the desired results.

The folding machines can be adapted to make these slits 46 and 48, or they can be made by a preceding operation, either before or after the pre-wrap 12 is aflixed to the blank 14.

Score lines 50 and 52 are formed on the bottom closure flaps 40 and 42, extending diagonally to the right from the locking notches 53 therein to the corners thereof, at the score line 32. These score lines provide foldable tug tabs 54 and 56 on the closure flaps 40 and 42.

4 In the illustrated embodiment, the tug tabs 54 and 56 are in the form of triangular-shaped corners, however, other different configurations can be provided. For example, the tug tabs can have curved or scalloped edges, to mention but a couple of the different configurations which can be used.

In folding the blank 14, with the pre-wrap 12 affixed to it, adhesive is applied along the length of the glue flap 29, and the glue flap 29 is then folded to secure it to the surface of the side wall 25. Then, the extending portions 57 and 58 of the pre-wrap are folded to overlie the bottom closure flaps 40 and 43, respectively, so that they are effectively tucked in the carton when it is erected. Next, all of the bottom closure flaps 40-43 are folded upward along the score line 32 so as to overlie the side walls 22-25, as illustrated in FIG. 4. Simultaneously, the tug tabs 54 and 56 are folded along the score lines 50 and 52, and in an opposite direction so as to overlie the bottom closure flaps 40 and 42, respectively, as illustrated in FIG. 5.

It may be noted that the slits 46 and 48 in the prewrap 12 permit these tug tabs 54 and 56 to be folded in this manner. It'may be further noted that by folding the tug tabs 54 and 56, two surfaces of the blank 14 are exposed. Adhesive isapplied to these surfaces and the side wall 22 then is folded along the score line 17 to overlie the side wall 23. The side wall 25 is likewise folded along the score line 19 to overlie the side wall 24. Prior to this latter fold, adhesive is applied to the exposed surface of the glue fiap 28 so that when the glue flap 29 is folded atop it, the two glue flaps are adhesively sealed together. The blank 14 after these folds are made appears as shown in FIGS. 6 and 7. The significant thing to note is that the tug tabs 54 and 56 are sandwiched between the bottom closure flaps 40, 41, and 42, 43, respectively, and that these tug tabs are adhesively afiixed to the prewrap 12 covering the closure flaps 41 and 43, respectively, so as to form back-to-face 0r board-to-face (carton to pre-wrap) anchor points or seals, as opposed to the faceto-face (pre-wrap to pro-wrap) seals of the prior art, at each of these positions. These back-to-face seals are far stronger than the face-to-face seals and virtually, if not completely, eliminate the seal breakage problem presently existing with the available cartons of the simulated prewrap type.

In the prior art, the bottom closure flaps 40 and 42 are generally considered to be the weakest of the four bottom closure flaps 40-43. As a result, it is usually found that they are not capable of functionally pulling the bottom closure fiaps 41 and 43 into a fully closed position to form a flat or level bottom on the carton. Applying additional force to the opposite corners of the carton 10 to fully form and level the bottom only causes the above described seals between the respective pairs of closure flaps to separate.

With the arrangement of the present invention, that is, with the tug tabs 54 and 56 folded and sandwiched between the bottom closure flaps 40, 41 and 42, 43, respectively, the closure flaps 40 and 42 become the stronger of the four flaps and are able to easily pull the closure flaps 41 and 43 into position to form a fully closed, level bottom on the carton. In FIGS. 8-11, the relative movement of the bottom closure flaps 40-43 with respect to one another, when a force is exerted upon the opposite corners 60 and 61 of the carton 10 to erect it is illustrated. The bottom closure flaps 40-43 are caused to fold downward toward a horizontally disposed, interlocked position, in generally the same fashion as the bottom closure flaps of the prior art. In this case, however, the tug tabs 54 and 56 are caused to unfold, along the score lines 50 and 52, respectively. This action tends to flatten or level the bottom closure flaps 40 and 41, as though a force were being exerted on them at the score lines 50 and 52, in the direction of the arrow 61. The tug tabs 54 and 56 being fixedly secured to the bottom closure flaps 41 and 43, in turn, forcibly pull these flaps into position to lockingly engage the locking notches 53 with one another to provide a level bottom on the carton. The back-to-face seals between the tug tabs 54 and 56 and the bottom closure flaps 41 and 43 are formed over a substantial area and are virtually breakproof so that the force necessary to assure a firm locked engagement between the locking notches can be applied to the carton without danger of these seals breaking. In fact, it is generally found that the carton will crush before the seals will break.

When the bottom closure flaps 4043 are positioned, the bottom 13 appears as illustrated in FIG. 2. It can be seen that the tug tabs 54 and 56 of the bottom closure flaps 40 and 42 are on the outside of the bottom 13, in overlapped relationship on the bottom closure flaps 41 and 43. The pre-wrap adjacent the score lines 50 and 52 is folded or creased so as to form lines which extend diagonally across the bottom and perpendicularly insert the diagonally extending edges of the bottom closure flaps 41 and 43 to provide a bottom having a handwrapped appearance.

With the above-described construction, it is found that in addition to providing a self-forming, self-leveling bottom on the cartons, a substantial savings in board material for the blank 14 is realized. This results from the fact that the bottom closure flaps 40 and 42 can be shortened to effect a savings of approximately 4.8% in material.

In the illustrated embodiment, the carton blank 14 is shown to have glue flaps 28 and 29 integrally affixed to the side walls 22 and 25, respectively. One of these glue flaps can be eliminated, if desired, and all of the advantages of the present invention are still provided. In this case, the pre-wrap 12 generally is folded over and affixed to the side of the blank shown so as to provide a back-to-face seal when the blank is folded to form the carton.

It will thus be seen that the objects set forth above, among those made apparent from the preceding description, are efiiciently attained and, since certain changes may be made in the above construction without departing from the scope of the invention, it is intended that all matter contained in the above description shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.

Now that the invention has been described, what is claimed as new and desired to be secured by Letters Patent is:

1. A flat-foldable carton having four lateral walls mutually joined in pairs to form upright edges, said walls having at one end thereof bottom closure flaps which are mutually interconnected to fold outward into a bottom for said carton as the walls are separated after being folded fiat, a simulated pre-wrap surrounding the outer surfaces of said walls and extending beyond the ends of the walls adjacent the bottom closure flaps and being secured to ones of said bottom closure flaps, a score line on at least two of said bottom closure flaps thereby defining foldable tug tabs, said pre-wrap being discontinuous between each of said bottom closure flaps having said tug tab integrally formed with it and the bottom closure flap immediately adjacent it to permit each of said tug tabs to be folded along said score lines and sandwiched between the bottom closure flap to which said tug tab is integrally affixed and another one of said bottom closure flaps when said carton is folded flat, said tug tabs being adhesively secured to respective ones of said other bottom closure flaps.

2. The flat-foldable carton of claim 1, wherein said pre-wrap has a slit formed in it between each of said bottom closure flaps having said tug tab integrally formed with it and the bottom closure flap immediately adjacent it.

3. The flat-foldable carton of claim 1 wherein said foldable tug tabs are triangular-shaped.

4. The flat-foldable carton of claim 1 wherein said tug tabs each provide a surface of said carton which is adhesively afiixed to said pre-wrap to provide a back-toface seal between them.

5. The flat-foldable carton of claim 1, wherein said tug tabs are exposed on the bottom of said carton when said carton is erected.

6. A flat-foldable carton having four lateral walls mutually joined in pairs to form upright edges, said walls having at one end thereof bottom closure flaps which are mutually interconnected to fold outward into a bottom for said carton as the walls are separated after being folded flat, a simulated pre-wrap surrounding the outer surfaces of said walls and extending beyond the ends of the walls adjacent the bottom closure flaps and being secured to ones of said bottom closure flaps, a score line on at least two of said bottom closure flaps for providing thereon foldable tug tabs, said pre-wrap being discontinuous between said bottom closure flaps having said tug tabs integrally formed with it and the bottom closure fiap immediately adjacent it, said tug tabs being folded along said score lines and sandwiched between the bottom closure flap to which said tug tab is integrally afiixed and another one of said bottom closure flaps when said carton is folded fiat thereby providing back-to-face anchor points between said tug tabs and said pre-wrap on said bottom closure flaps on the bottom of said carton, thereby insuring a back-to-face relationship at all bottom anchor points, said tug tabs being adhesively secured to said pre-wrap on said bottom closure flaps.

7. A flat-foldable carton having four lateral walls mutually joined in pairs to form upright edges, said walls having at one end thereof bottom closure flaps which are mutually interconnected to fold outward into a bottom for said carton as the walls are separated after being folded flat, interlocking means on at least two of said bottom closure flaps, a simulated pre-wrap surrounding the outer surfaces of said walls and extending beyond the ends of the walls adjacent the bottom closure flaps and being secured to ones of said bottom closure flaps, a score line on at least two of said bottom closure flaps for providing thereon foldable tug tabs, said pre-wrap having a slit in it between each of said bottom closure flaps having said tug tabs integrally formed with it and the bottom closure flap immediately adjacent it, said tug tabs being folded along said score lines and sandwiched between the bottom closure flap to which said tug tab is integrally affixed and another one of said bottom closure flaps when said carton is folded fiat thereby providing back-to-face anchor points between said tug tabs and said pre-wrap on said bottom closure flaps on the bottom of said carton, thereby insuring a back-to-face relationship at all bottom anchor points, said tug tabs being unfolded along said score lines as said walls are separated and urging both its integrally afiixed bottom closure flap and said other bottom closure flap to which it is affixed to unfold downwardly to engage said interlocking means to fixedly retain said bottom closure flaps in a level position, to thereby provide a self-form, self-leveling bottom on said carton.

8. A flat-foldable carton having four lateral walls mutually joined in pairs to form upright edges, said walls having at one end thereof bottom closure flaps shaped to interlock with one another to form a self-leveling bottom for said carton when the carton is erected, a simulated pre-wrap surrounding the outer surfaces of said walls and extending beyond the ends of said walls and being secured to ones of said bottom closure flaps, interlocking leveling means on predetermined ones of said bot-tom closure flaps normally sandwiched between the bottom closure flaps to which they are affixed and other ones of said bottom closure flaps and secured at anchor points to said other ones of said bottom closure flaps when said carton is folded flat and exposed on the bottom when said carton is erected, a slit in said pre-wrap between said bottom 7 8 closure flaps having said interlocking leveling means on 2,963,212 12/1960 Gastright 22939 XR them and the bottom closure flap immediately adjacent 2,990,099 6/1961 Ryder 229- 39 them to permit said interlocking leveling means to be 3,057,535 10/1962 Thompson 229-39 sandwiched and secured in the described fashion. 3,257,068 6/1966 Wright.-

References Cited 5 DAVIS T. MOORHEAD, Primary Examiner.

UNITED STATES PATENTS 2,479,456 3/1949 Arthur. 2,716,519 3/1955 Rafoth etal 229-39 US. Cl. X.R. 

